Construction method for sound wall panels and adjustable soundwall barriers

ABSTRACT

A method of constructing a soundwall comprises forming a back panel comprising a longitudinal wall connecting two opposing end walls, such that the end walls are relatively perpendicular to the longitudinal wall, wherein each opposing end wall has a first end and a second end, wherein the end wall first end joins the longitudinal wall, and the end wall second end has a perpendicular attachment mechanism, for attachment relatively perpendicular to the end wall. The back panel is then filled with a sound absorbing core, which is then enclosed by attachment of a of a perforated front panel to the back panel end wall perpendicular attachment mechanism. The front panel has opposing panel ends, wherein the end wall perpendicular attachment mechanism comprises a u-shaped protrusion at the end wall second end, wherein the u-shape is generally perpendicular to the end wall, and further, wherein the perforated front panel ends each have a mating u-shape.

This application claims the benefit of U.S. Provisional Application No. 60/713,166 filed Aug. 31, 2005.

BACKGROUND

The present invention is in the field of sound reduction/absorption. More specifically, the invention relates to method of construction for soundwalls typically used along the roadway.

Soundwalls have long been used to separate communities from roadways. They serve a dual purpose of eliminating the view of the roadway from the community, and most importantly, reducing traffic noise from the roadway within the community.

A typical soundwall is from 8 to 18 feet in height, and runs continuously along a section of roadway. Installation of these types of soundwalls is labor intensive, expensive, and subject to problems in the field, which cannot be remedied in the field.

A typical construction comprises installing vertical support posts at a specified distance apart, and then stacking sound panels between these posts until a desired height is reached. For example, see the Sound Fighter® System, or U.S. Pat. No. 5,272,284 to Schmanski. This requires posts to be installed typically every 6 feet, and if the posts are not installed correctly, the panels will not fit. This requires adjustment of the position of all the installed posts, or some type of machining of the sound panels to insure a proper fit.

Another type of construction requires installing vertical posts, and lifting a large single sound panel over the posts, and sliding it down onto the posts. (See for example U.S. Pat. No. 5,965,852 to Roschke). This does not allow for any adjustment in the field, as the size of the panels is already set. Further, this requires a lifting mechanism to lift the entire panel over the vertical post, such that it can be lowered into place.

A soundwall construction method is desired which would be less labor intensive, would not require complicated lifting mechanisms, and would allow for adjustment in the field.

SUMMARY

A method of constructing a soundwall comprises forming a back panel comprising a longitudinal wall connecting two opposing end walls, such that the end walls are relatively perpendicular to the longitudinal wall, wherein each opposing end wall has a first end and a second end, wherein the end wall first end joins the longitudinal wall, and the end wall second end has a perpendicular attachment mechanism, for attachment relatively perpendicular to the end wall. The back panel is then filled with a sound absorbing core, which is then enclosed by attachment of a of a perforated front panel to the back panel end wall perpendicular attachment mechanism. The front panel has opposing panel ends, wherein the end wall perpendicular attachment mechanism comprises a u-shaped protrusion at the end wall second end, wherein the u-shape is generally perpendicular to the end wall, and further, wherein the perforated front panel ends each have a mating u-shape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of an adjustable soundwall barrier according to an aspect of the invention.

FIG. 2 is an isometric view of a vertical sound panel assembly, according to an aspect of the invention.

FIG. 3 is a cross section from FIG. 2, according to an aspect of the invention.

FIG. 4 is an isometric view of a channel according to an aspect of the invention.

FIG. 5 is an isometric view of a channel according to an aspect of the invention.

DETAILED DESCRIPTION

Various aspects of the invention are presented in FIGS. 1-3 which are not drawn to scale and in which like components are numbered alike. Referring now to these figures, according to an aspect of the invention, a method of constructing an adjustable soundwall barrier 10 on a supporting surface 1, comprises the steps of installing a first vertical support post 20, laying a first channel 30 on the supporting surface 1, connecting a plurality of vertical sound panels 40 together, placing the connected vertical sound panels 40 into the first channel 30, installing a second vertical post 50, and capping the assembly with a second channel 60.

The first vertical support post 20 should have a height 22 approximately equal to the desired sound wall height 12. It is installed into the supporting surface 1, typically the ground. The desired distance between vertical support posts should be determined on a case by case basis, taking into account the desired height of the soundwall, the changing topography of the supporting surface, and any expected environmental conditions, such as typical wind strength, or vibration loads. Typically however, this type of installation allows for 10 to 12 feet between the vertical support posts, as compared to 6 feet for most others. This reduces material costs, as well as significantly reducing labor costs.

When the desired distance between vertical support posts 20 and 50 has been determined, a first channel 30 of a desired length 32, which is approximately the desired distance between these vertical support posts, is laid on the supporting surface 1. The first channel 30 has a first end 36, and an opposing second end 38, such that the first channel 30 is secured to the vertical support post 20 at the first channel first end 36.

The vertical sound panels 40 have a perforated front face 42, to face the sound source, and a solid back face 44, opposing the front face 42, and is filled with sound absorption material 43 between the front face 42 and the back face 44. The vertical sound panels 40 have a height 45 approximately equal to the height of the vertical support posts. The vertical sound panels 40 can be manufactured to whatever size is necessary. Therefore, when the desired height of the soundwall for a particular area is determined, the vertical sound panels 40 can be manufactured to that height. Various heights of vertical sound panels 40 can then be provided to adjust to the various desired heights of the soundwall along the length of the soundwall 10. The vertical sound panels 40 further have opposing longitudinal sides 46, wherein the longitudinal sides 46 each have an attachment mechanism 48 along the longitudinal side 46 for attachment to an adjacent vertical sound panel 40. The vertical sound panels 40 are connected via the attachment mechanisms 48 to form a sound panel assembly 41 which is the desired size, approximately equal to the channel length 32.

The vertical sound panels 40 have a top end 47 and a bottom end 49, approximately perpendicular to the longitudinal sides 46. The sound panel assembly 41 is then placed into the first channel 30, such that the vertical sound panel bottom ends 49 are placed into the channel 30.

A second vertical support post 50 is then installed at the first channel second end 38, such that first channel second end 38 is secured to the second vertical support post 50.

A second channel 60 of a length approximately equal to the first channel length 32 is then placed on the top end 47 of the vertical sound panels 40, wherein the second channel 60 has opposing ends 62, such that the second channel 60 is secured to the vertical support posts at each end 62.

According to an aspect of the invention, the above steps may then be repeated from the second vertical support post 50 to a third vertical support post 70, and so-on. The height of a third vertical support post 70 may vary from the first and second, as may the height of the vertical sound panels 40. This would just require securing the channel which sits on the top end 47 of the vertical sound panels 40 to a portion of the vertical support post which might not be the top. This can be seen in FIG. 1.

According to a further aspect of the invention, the attachment mechanism 48 comprises a u-shaped protrusion along the longitudinal side 46, such that an adjacent vertical sound panel 40 with a mating u-shaped protrusion may be slid, or snapped into a mating position. Thus these may be connected, or disconnected in the field if necessary. Further, the attachment along the entire length of the vertical sound panel allows for connection without worrying about lining up any attachment mechanisms.

According to another aspect of the invention, this attachment mechanism along the entire length of the mating surfaces may also be used to uniquely construct the vertical sound panels 40 themselves. Where the vertical sound panels 40 have a perforated front face 42, to face the sound source, and a solid back face 44, opposing the front face 42, and is filled with sound absorption material 43 between the front face 42 and the back face 44, as described above. The entire vertical sound panel 40 has a relatively rectangular cross-section 80, wherein the front face 42 comprises one longitudinal wall 81 of this rectangle 80, and the back face 44 comprises the other longitudinal wall 82, and the opposing end walls 84.

Each opposing end wall 84 has a first end 83 and a second end 85, wherein the end wall first end 83 joins the longitudinal wall 81, and the end wall second end 85 comprises a perpendicular attachment mechanism 88, for attachment relatively perpendicular to the end wall 84. Thus a vertical sound panel 40 can be constructed by forming the back face 44 as such, for example by pull-truding, filling the back panel with a sound absorbing core 43, and enclosing the sound absorbing core 43 by attachment of a perforated front panel 42 to the back panel end wall perpendicular attachment mechanism 88. According to an aspect of the invention, the front panel 42 has opposing ends 86, wherein these opposing ends 86 each have a mating perpendicular attachment mechanism 87 for attachment along the vertical sound panel 40. According to an aspect of the invention, the attachment mechanism 88 comprises a unshaped protrusion at the end wall second end 85, wherein the u-shape is generally perpendicular to the end wall 84, wherein the u-shaped protrusion is all along the length of the back panel 44, and the front panel attachment mechanism 87 comprises a mating u-shaped protrusion along the length of the front panel 42. The front panel 42 may then be slid into place along the back panel 44, or it may be snapped into place by slightly compressing the end walls 84. 

1. A method of constructing a soundwall comprising: forming a back panel comprising a longitudinal wall connecting two opposing end walls, such that the end walls are relatively perpendicular to said longitudinal wall, wherein each opposing end wall has a first end and a second end, wherein said end wall first end joins said longitudinal wall, and said end wall second end has a perpendicular attachment mechanism, for attachment relatively perpendicular to said end wall; filling said back panel with a sound absorbing core; and, enclosing said sound absorbing core by attachment of a perforated front panel to said back panel end wall perpendicular attachment mechanism.
 2. The method of claim 1 wherein said end wall perpendicular attachment mechanism is such that said front panel may be attached without use of fasteners.
 3. The method of claim 1 wherein said front panel has opposing panel ends, wherein said end wall perpendicular attachment mechanism comprises a u-shaped protrusion at said end wall second end, wherein said u-shape is generally perpendicular to said end wall, and further, wherein said perforated front panel ends each have a mating u-shape.
 4. The method of claim 3 wherein said front panel is slid through said perpendicular attachment mechanism
 5. The method of claim 1 wherein said front panel is snapped into place.
 6. Method of constructing an adjustable soundwall barrier on a supporting surface, comprising the steps: installing a first vertical support post having a height of a desired sound wall height into the supporting surface; laying a desired length of first channel on the supporting surface, wherein said first channel has a first end, and an opposing second end, such that said first channel is secured to said vertical support post at said first end; connecting a plurality of vertical sound panels together, wherein said sound panels have a perforated front face to face the sound source, and a solid back face, opposing said front face, and wherein said sound panel is filled with sound absorption material between said front face and said back face, further wherein said vertical sound panels have a height approximately equal to the height of said vertical support posts, and further wherein said sound panels have opposing longitudinal sides, said longitudinal sides each having an attachment mechanism along said longitudinal side for attachment to an adjacent sound panel, wherein said sound panels are connected via said attachment mechanisms to form a desired size, approximately equal to said channel length; mounting said connected vertical sound absorbing panels into the channel, wherein said vertical sound panels have a top end and a bottom end, approximately perpendicular to said longitudinal sides, wherein said vertical sound panel bottom ends are placed into said channel; installing a second vertical support post at said channel second end, such that said channel second end is secured to said second vertical post; and, placing a second channel of a length equal to said first channel length over top of said vertical sound panels, wherein said second channel has opposing ends, such that said second channel is secured to said vertical posts at each end.
 7. The method of claim 6 further comprising the step of repeating the steps of claim 6 from said second vertical post to a third vertical post.
 8. The method of claim 6 wherein said attachment mechanism comprises a u-shaped protrusion along said longitudinal side, such that an adjacent vertical sound panel with a mating unshaped protrusion may be slid, or snapped into a mating position. 